Internal combustion engine

ABSTRACT

Internal combustion engines having a split crankshaft are disclosed. The engines may also have non-circular, preferably rectangular, cross-section pistons and cylinders. The pistons may include a skirt with a field of pockets that provide a ringless, non-lubricated, seal equivalent. The pistons also may have a domed piston head with depressions thereon to facilitate the movement of air/charge in the cylinder. The engines also may use multi-stage poppet valves in lieu of conventional poppet valves. The engines may use the pumping motion of the engine piston to supercharge the cylinder with air/charge. The engines also may operate in an inverted orientation in which the piston is closer to the local gravitationally dominant terrestrial body&#39;s center of gravity at top dead center position than at bottom dead center position.

CROSS REFERENCE TO RELATED APPLICATIONS

This application relates to and claims the priority of U.S. provisionalpatent application Ser. No. 62/501,295, which was filed May 4, 2017; andU.S. provisional patent application Ser. No. 62/479,013, which was filedMar. 30, 2017; and U.S. provisional patent application Ser. No.62/491,629, which was filed Apr. 28, 2017; and U.S. patent applicationSer. No. 15/903,636, which was filed Feb. 23, 2018.

FIELD OF THE INVENTION

The present invention relates generally to internal combustion enginesand methods of engine operation.

BACKGROUND OF THE INVENTION

Many internal combustion engines utilize cooperative engine cylinder andpiston arrangements to generate power using a pumping motion. Enginecylinder and piston arrangements may be used to intake or scavenge anair-fuel mixture or strictly air charge (in fuel injected engines) forcombustion and expel spent exhaust gases in multicycle operations, suchas, for example, in 2-cycle and 4-cycle operations. While embodiments ofthe present invention have primary use for 4-cycle engine operation, theclaims defining the invention are not limited to 4-cycle engines unlesssuch limitation is expressly set forth in the claims.

Further, it is to be appreciated that the reference herein to an engine“cylinder” is not limited to a combustion chamber having a cylindricalshape or circular cross-section. Instead, the term cylinder refers toany combustion chamber or cavity of any shape that receives a pistonhaving an outer shape adapted to effectively seal (i.e., to permit anacceptable level of leakage) with the sidewall of the cylinder. The sealshould be in effect as the piston slides back and forth reciprocallywithin the engine cylinder in a pumping motion.

Engine cylinders may include one or more intake ports and one or moreexhaust ports that, collectively, permit gases to flow into, and out of,the engine cylinder, respectively. Engine valves, such as poppet valves,may be used to selectively open and close the intake and exhaust ports.The selectively timed opening and closing of the intake and exhaustvalves, in conjunction with the pumping motion of the engine pistons andthe introduction of fuel, may provide an air/fuel charge to the enginecylinder for combustion and removal of the spent charge exhaust gasesfrom the cylinder after combustion.

Existing internal combustion engine pistons used for Otto cycle orDiesel cycle operation, for example, typically have a generallycylindrical shape. More specifically, the typical Otto or Diesel cycleengine piston may have a generally smooth cylindrically shaped skirtwith a circular cross-section that includes circumferential recesses toreceive one or more sealing piston rings. The piston and piston ringassembly may slide reciprocally within a cylinder between top deadcenter and bottom dead center positions. The interface of the pistonrings with the cylinder wall may be lubricated with engine oil, forexample.

The efficiency of a particular engine design may be a function of manyfactors. Among others, these factors include engine weight to powerratio, as well as the overhead space available for the placement ofintake valves, exhaust valves, auxiliary valves, spark plugs, glowplugs, fuel injectors and water injectors. Engine power is often afunction, at least in part, of cylinder displacement. Engine weight is afunction, at least in part, of the space required to house the enginepistons, which is a function of the engine cylinder and piston shape.Cylindrically shaped engine pistons require a certain amount of spaceper unit volume of displacement, and the required space is a function ofthe diameter of the piston skirt. The overhead space available for theplacement of intake valves, exhaust valves, auxiliary valves, sparkplugs, glow plugs, fuel injectors and water injectors in cylindricallyshaped engine pistons is also limited by (i.e., a function of) thediameter of the piston skirt. Accordingly, circular cross-section enginecylinders and pistons may be less desirable in terms of engine space,weight and overhead space, than non-circular cross-section pistons andcylinders, for a given engine displacement and power rating.

Honda developed one known example of a non-circular cross-section enginepiston for a motorcycle engine. Honda's oval piston internal combustionengine is described in U.S. Pat. No. 4,383,508 to Irimajiri et al. Hondaemployed oval pistons to obtain increased cylinder displacement andincreased overhead area available for valves, spark plugs, andinjectors. However, Honda's oval shaped piston engine was not optimal,and required the use of two connecting rods between each piston and thecrankshaft, thereby increasing the weight and size of the overallengine. The Honda oval pistons also required the use of specialtechnology to keep the pistons moving parallel to the cylinder blockwalls, thereby increasing weight and complexity of the engine.Accordingly, there is a need for engines with non-circular cross-sectioncylinders and pistons that improve upon the Honda implementation interms of weight, space required, and the placement of intake valves,exhaust valves, auxiliary valves, spark plugs, glow plugs, fuelinjectors and water injectors.

Two additional factors which impact engine efficiency are flame frontpropagation during combustion of fuel, and effective force transfer fromthe expansion of combustion gases to the piston used to generate power.Pistons having an upper end or head with a hemispherical or domed shapeare known for their efficient flame front propagation properties andeffective force transfer of combustion gases to piston. However,hemispherical pistons were not utilized in engines with non-circularcross-section cylinders and pistons. Accordingly, there is a need forpistons with hemispherical or domed heads to be used in engines withnon-circular cross-section cylinders and pistons.

Engine space and weight is also a function of crankshaft and connectorrod design. As already noted, the Honda engine employing particular ovalcross-section pistons required two connector rods per piston, therebyincreasing engine weight and complexity. Accordingly, there is a needfor compact crankshaft and connector rod assemblies for use withnon-circular cross-section pistons in particular, and for all enginesgenerally, that is optimal in terms of weight, required space, cost,and/or reliability.

The manufacturing cost and the repair cost are also factors that requireconsideration for commercialization of the engines. Crankshaftassemblies typically require the use of splined elements to join theconstituent elements, such as shafts, and cranks, together. Splinedelements may require relatively expensive manufacturing processes toproduce, and are relatively difficult and expensive to repair. Moreover,it is desirable for some engines to permit the center shaft of acrankshaft assembly to break away cleanly from the other elements towhich it is connected during an engine failure condition. Crankshaftelements joined using splines are not well suited to break away fromeach other during an engine failure, and if they were designed to do so,repair would likely be difficult and expensive. Accordingly, there is aneed for crankshaft assemblies that do not require splined elements tojoin the constituent parts of the assemblies together.

Internal combustion engines almost universally require liquid lubricant,such as engine oil, to lubricate the interface between the piston andthe cylinder within which it moves back and forth in a reciprocalmotion. Lubrication systems are usually mission critical and the failureof a lubrication system can be catastrophic. The need for a pistonlubricant brings with it many disadvantages. The lubricant wears out andbecomes contaminated over time, and thus requires replacement, addingexpense and inconvenience to engine operation. Many lubricants requirepumps and passages to reapply the lubricant to moving parts, such as theengine pistons. Pumps and passages, and other elements of an activelubrication system need to operate correctly and require seals betweeninterconnected elements. Lubrication system leaks naturally occur asseals deteriorate over time, and pumps leak and wear out, adding stillfurther maintenance expense and inconvenience to engine operation. Leakscan also permit lubricant to enter the combustion chamber, interferingwith combustion, and fouling injectors and spark or glow plugs.Lubricant in the combustion chamber can also result in unwanted exhaustemissions. Leaks can also result in the contamination of the lubricantwith combustion by-products. All of the foregoing issues are attendantto the use of lubricated pistons, and all add failure modes andmaintenance costs. Accordingly, there is a need for internal combustionengines that depend less, or not at all, on piston lubrication.

Engine efficiency and power may also be a function of the mass of air inthe combustion chamber. The air mass that can be loaded into thecombustion chamber is a function of the pressure differential betweenthe combustion chamber and the intake air source (e.g., manifold) duringthe intake cycle, as well as the effective size and flow characteristicsof the intake port, and the duration of the intake cycle event.Increasing any one or more of the intake air pressure, the effectivesize and/or flow profile of the intake port, and/or the effective intakecycle duration, will tend to increase air mass in the combustionchamber, and thus improve efficiency and power. Accordingly, there is aneed for engines and methods of engine operation that increase and/orimprove intake air pressure, intake port size and flow, and/or intakeevent duration.

In addition to improving air mass transfer to the engine cylinder forcombustion, improved engine efficiency and power may also result fromoptimal swirl and turbulence of the intake air or air/fuel mixtures incylinder squish areas. The swirl and turbulence produced in squish areasis a function of numerous factors, including the shape of the upper endof the piston and cylinder head defining the combustion chamber.Accordingly, there is a need for engine pistons and cylinders shaped topromote optimal swirl and turbulence in the combustion chamber squishareas.

Engine efficiency and power, resulting from air mass transfer to theengine cylinder for combustion for example, may also be a function ofthe timing of the opening and closing of engine intake valves. Thetiming for opening and closing exhaust and auxiliary valves can alsoaffect efficiency and power. Conventional fixed time valve actuation maybe set to be optimal for one set of engine operation parameters (e.g.,ambient temperature, pressure, fuel type and richness of mixture, enginespeed and load, etc.). Fixed time valve actuation may be sub-optimal forall other combinations of engine operation conditions. In order toprovide improved efficiency and power, engines have been provided withvariable valve actuators (VVA), however the control of existing VVAsystems may be complicated and expensive. Accordingly, there is a needfor intake, exhaust, and auxiliary variable valve actuation systems thatprovide variable valve timing without the need for overly complicated orexpensive componentry.

Some vehicles and other engine powered machines may benefit from engineshaving a low center of mass relative to the vehicle or machinestructure. A low center of mass may improve handling characteristics,for example. Known internal combustion engines have centers of massdictated, at least in part, by the need to place heavy cylinder headsand associated components at the top of the engines. The location of thecylinder heads at the top of the engines results from the need tolubricate the pistons in a manner that restricts the amount oflubricating oil that enters the combustion chambers. Accordingly, thereis a need for engines with innovative piston lubrication solutions. Newlubrication systems, methods and/or substitutes may eliminate the needto place heavy cylinder heads and associated components at the top ofthe engine thereby permitting the design of engines with a lower centerof mass compared to other engines of comparable weight, power and cost.

OBJECTS OF THE INVENTION

Accordingly, it is an object of some, but not necessarily allembodiments of the present invention to provide engines and methods ofengine operation that decrease the amount of space required for anengine of a given displacement and/or power rating by using enginepistons with a non-circular cross-section. It is also an object of some,but not necessarily all embodiments of the present invention to provideengines and methods of engine operation that decrease the weight of anengine of a given displacement and/or power rating by using enginepistons with a non-circular cross-section. Engines with non-circularcross-section cylinders and pistons may produce the same power as acircular cross-section cylinder engine with less wasted space becausethe pistons are located closer to one another, thereby decreasing theengine weight and effectively increasing the power to weight ratio ofthe engine. In particular, engines with rounded corner rectangular orstretched oval cross-sectional shapes may provide improved weight topower ratio.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines with increased overhead space forthe placement of intake valves, exhaust valves, auxiliary valves, sparkplugs, glow plugs, fuel injectors and water injectors. Non-circularcross-section cylinders may provide more head surface area than circularcross-section cylinders in engines of comparable weight.

It is also an object of some, but not necessarily all, embodiments ofthe present invention to provide engines and methods of engine operationthat permit a spark plug, glow plug, water injector, and/or fuelinjector to be centrally located over the piston in an area of squishand/or turbulence. By locating the injector near the center of thepiston near the spark or glow plug, and in the more turbulent area ofsquish and swirl, fuel may be injected during the appropriate timesaround top dead center with appropriate mixing into the compressedgasses thereby allowing an improved ratio mix or a localized lean mix ofthe compressed charge. This may allow more radical valve timing toachieve chamber blow-down without unspent fuel loss through the exhaustport and permit a shallower compression stroke by allowing some of theintake air to be returned to the intake before closing the intake valve,thereby generating a comparably longer expansion stroke.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines, and methods of engine operationthat utilize cooperative engine piston head and cylinder shapes thatinclude an upper surface that is non-flat, preferably curved or domed,more preferably semi-hemispherical, and even more preferably includesone or more depressions. In this regard, it is also an object of some,but not necessarily all embodiments of the present invention to provideengine piston head and cylinder shapes that promote swirl and turbulencein the engine cylinder.

It is also an object of some, but not necessarily all, embodiments ofthe present invention to provide engines, methods of enginemanufacturing, and methods of engine operation that promote an optimaland/or shortened flame front propagation during combustion.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationthat eliminate the need to lubricate the piston-cylinder interface,thereby reducing engine complexity, cost, and maintenance requirements.In this regard, some embodiments of the present invention may employcooperatively shaped pistons and cylinder walls that have surfacefeatures that form an effective seal equivalent between them without theneed for piston rings or lubrication.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationthat decrease the weight of an engine of a given displacement and/orpower rating by using the engine pistons to boost the pressure of intakeair provided to the engine cylinders for combustion. In this regard, thesealed cavity under the piston may be used in a two-stroke process toact as a compressor and boost intake pressure like a supercharger. Thispermits previously underutilized space to be more efficiently employedto benefit engine power. Locating the “supercharger” directly within theengine may reduce associated power losses due to pumping and powertransfer when compared with an externally located superchargers drivenby pulleys, belts, or gears from a crankshaft output.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operation inwhich the combustion and supercharger chambers are sealed usinglubricant (e.g., oil) transported through the piston to directly prime,pressurize, and lubricate these seals.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operation inwhich excess leakage between the combustion chamber and thesupercharging chamber are recirculated to the combustion chamber by thesupercharger process as charge recapture and/or exhaust gasrecirculation to reduce emissions. It is also an object of some, but notnecessarily all embodiments of the present invention to reduce leakagefrom the combustion chamber into the crankcase as the superchargerchamber may act as a diluting buffer between the combustion chamber andthe crankcase.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationthat limit or prevent the infiltration of oil into the combustion andsupercharging chambers, thereby reducing objectionable emissions. Byremoving oil from the system, where practical, the oil aerosols areeliminated from the exhaust gasses, thereby preventing oil and oilby-product accumulation on the valves, injectors, spark plugs,turbochargers, catalytic converters, and other engine system components.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationthat limit or prevent the infiltration of combustion by products andby-products into the oil, which can introduce carbon particles, unspenthydro-carbons, and other particulates which can contaminate and modifythe pH of the oil. Reducing or eliminating these oil contaminationsources may prevent oil system corrosion and prolong the oil servicelife thereby decreasing required maintenance costs and decreasingancillary oil handling, stocking, and recycling costs.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationwith more compact and lighter crankshaft, connecting rod, and cross-headassemblies. It is also an object of some, but not necessarily allembodiments of the present invention to provide engines and methods ofengine operation with crankshaft, connecting rod, and cross-headassemblies configured for use with engine cylinders and pistons withnon-circular cross-sections.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationwith break-away engine components, such as cranks on the crankshaft. Tothis end, some engine components, such as shafts and cranks may bejoined using multiple commercially mass produced pins or keys withoutthe use of splined elements, which tend to require expensivemanufacturing processes. The multiple pins or keys may create areplaceable spline-like structure to transmit torque and rotationalenergy that will shear during abnormal operating conditions to preservethe engine while allowing only minimal damage to the two joinedelements. After a failure, the shorn pins or keys can be replacedquickly to decrease down-time.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operationwith a multi-stage telescoping poppet valve. Using a multi-stage poppetvalve, a set volume of air can be loaded into the engine cylinder fasterand with less restriction, which may reduce pumping losses and improveoperation at high RPM ranges. The multi-stage poppet valve design mayallow a portion of the inner valve surface area to be opened for airflow. In a fixed embodiment, this design may allow some poppet valvemoving mass to be removed from the valve train, allowing the valve toopen slightly faster and to maintain control without floating atslightly higher RPMs. This valve design may be used with an additionalvalve train (e.g., independent cam, rocker or VVA) allowing theindividual inner and outer valves to actuate independently. This maycreate a multi-stage variable aperture valve with both inner and outersections able to be controlled with variable valve timing dependent uponengine conditions. A control strategy may also allow this valve designto replace a separate throttle plate, as the valve itself can act as acomputer controllable variable restriction in the engine's intake path.

It is also an object of some, but not necessarily all embodiments of thepresent invention to provide engines and methods of engine operation inwhich the engine normally operates in an inverted or piston head downorientation. Engines in which the pistons and cylinder heads are belowthe crankshaft (i.e., closer to the center of the local gravitationallydominant terrestrial body) may have a comparably lower center of massthan conventionally oriented engines. This lower center of mass mayprovide advantages to engine operation, and when the engine is mountedin a vehicle, advantages to vehicle operation.

These and other advantages of some, but not necessarily all, embodimentsof the present invention will be apparent to those of ordinary skill inthe art.

SUMMARY OF THE INVENTION

Responsive to the foregoing challenges, Applicant has developed aninnovative internal combustion engine comprising: an internal combustionengine comprising: an engine cylinder having a cylinder wall; a pistondisposed in the engine cylinder, said piston having a skirt and a head;a combustion chamber adjacent to the piston head defined by the cylinderwall; a first cross-head guide disposed proximal to the piston; a secondcross-head guide disposed distal from the piston; a cross-head connectedto the piston, said cross-head extending between and slidably receivedby the first cross-head guide and the second cross-head guide; twoconnecting rods each having a first end pivotally connected to thecross-head, and a second end distal from the first end, wherein the twoconnecting rods are disposed on opposites sides of the cross-head andrigidly connected to each other; a first crank disposed in a crankcaseand pivotally connected to the second end of a first of the twoconnecting rods; a second crank disposed in the crankcase and pivotallyconnected to the second end of a second of the two connecting rods; afirst split crankshaft section connected to the first crank; and asecond split crankshaft section connected to the second crank.

Applicant has further developed an innovative internal combustion enginecomprising: an engine cylinder having a cylinder wall; a piston disposedin the engine cylinder, said piston having a skirt and a head; acombustion chamber adjacent to the piston head defined by the cylinderwall; a first cross-head guide disposed proximal to the piston; a secondcross-head guide disposed distal from the piston; a crankcase disposedbetween the first cross-head guide and the second cross-head guide; across-head connected to the piston, said cross-head extending betweenand slidably received by the first cross-head guide and the secondcross-head guide, said cross-head having a lower extension; and an oilreservoir connected to the crankcase by one or more drain passages,wherein the cross-head lower extension is configured to agitate oil inthe oil reservoir as a result of engine operation.

Applicant has still further developed an innovative internal combustionengine comprising: an engine cylinder having a cylinder wall; a pistondisposed in the engine cylinder, said piston having a skirt and a head;a combustion chamber adjacent to the piston head defined by the cylinderwall; a crank connected through one or more members to the piston, saidcrank having a plurality of crank keyholes formed in the crank; acrankshaft member, said crankshaft member having a plurality ofcrankshaft keyholes formed in the crankshaft section; and a plurality ofpins/keys disposed in and extending between the plurality of crankkeyholes and the plurality of crankshaft keyholes.

Applicant has still further developed an innovative method oflubricating a crankshaft assembly in an internal combustion engine,comprising the steps of: providing lubricant in an engine reservoir;providing a crankcase in which the crankshaft assembly including across-head operate, said cross-head having a lower extension thatcontacts the lubricant in the engine reservoir; and agitating thelubricant in the engine reservoir using motion of the lower extension ofthe cross-head.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory only,and are not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to assist the understanding of this invention, reference willnow be made to the appended drawings, in which like reference charactersrefer to like elements. The drawings are exemplary only, and should notbe construed as limiting the invention.

FIG. 1 is a partial cross-sectional end view of an internal combustionengine cylinder, piston, crankcase, and oil pan in accordance with afirst embodiment of the present invention.

FIG. 2 is a side view of a crankshaft, connecting rod, and cross-headassembly in accordance with the first embodiment of the presentinvention.

FIG. 3 is a partial cross-sectional view of an internal combustionengine cylinder, piston, and intake supercharger/intercooler inaccordance with a second embodiment of the present invention.

FIG. 4A is an isometric view of a rectangular piston in accordance withthe first embodiment of the present invention.

FIG. 4B is a top plan view of the rectangular piston of FIG. 4A.

FIG. 4C is a side, partial cross-sectional, view of the rectangularpiston of FIG. 4A.

FIG. 5A is an isometric view of a rectangular piston for use inalternative embodiments of the present invention.

FIG. 5B is a top plan view of the rectangular piston of FIG. 5A.

FIG. 5C is a side, partial cross-sectional, view of the rectangularpiston of FIG. 5A.

FIG. 6 is an exploded view of a crank, crankshaft, and joining elementsin accordance with the first embodiment of the present invention.

FIG. 7A is an isometric view of the separated outer and inner elements,respectively, of a multi-stage telescoping poppet valve in accordancewith the first embodiment of the present invention.

FIG. 7B is an isometric, partial cross-sectional, view of a multi-stagetelescoping poppet valve constructed of outer and inner elements shownin FIG. 7A in a valve-closed position.

FIG. 7C is an isometric, partial cross-sectional, view of themulti-stage telescoping poppet valve of FIG. 7B in a valve-openedposition.

FIG. 7D is a side view of the multi-stage telescoping poppet valve ofFIG. 7B.

FIG. 7E is a cross-sectional view of the multi-stage telescoping poppetvalve of FIG. 7D.

FIG. 7F is an isometric view of the separated outer and inner elements,respectively, of a multi-stage telescoping poppet valve in accordancewith a fourth embodiment of the present invention.

FIG. 7G is a side view of a multi-stage telescoping poppet valveconstructed of outer and inner elements shown in FIG. 7F in avalve-closed position.

FIG. 7H is a side view of the multi-stage telescoping poppet valve ofFIG. 7G in a valve-opened position.

FIG. 7I is a cross-sectional view of the multi-stage telescoping poppetvalve of FIG. 7H.

FIG. 8A is a side view of the poppet valve of FIGS. 7A-7E and a valveactuation system for the poppet valve in accordance with the firstembodiment of the present invention.

FIG. 8B is a side view of the poppet valve of FIGS. 7A-7E and a valveactuation system for the poppet valve in accordance with a fifthembodiment of the present invention.

FIG. 8C is a side view of the valve actuation system of FIG. 8A usedwith a poppet valve of FIGS. 7F-7I.

FIG. 9 is a side view of an inverted orientation internal combustionengine in accordance with a sixth embodiment of the present invention.

FIG. 10A is an isometric, partial cross-sectional, view of an invertedorientation internal combustion engine in accordance with a seventhembodiment of the present invention.

FIG. 10B is a cross-sectional end view of the internal combustion engineof FIG. 10A.

FIG. 10C is a side view of a lubricated engine piston and crankshaftarrangement shown in FIGS. 10A and 10B.

FIG. 10D is a top plan view of the engine piston shown in FIG. 10C.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings. With reference to FIG. 1, an end-on partial cross-sectionalview is provided of an engine piston 36, cylinder head 37, engine block38, crankcase 39, and oil reservoir 45, in accordance with a firstembodiment of the invention. The engine may be oriented with thecylinder head 37 at an upper end, i.e., with the center of mass of thecylinder head further away from the center of gravity of the localgravitationally dominant terrestrial body (e.g., Earth) than the centerof mass of the engine block 38.

The cylinder head 37 may be sealed to the engine block 38. The upperwalls of the cylinder head 37 and the engine block 38 define acombustion chamber 21 above the piston 36. The seal between the cylinderhead 37 and the engine block 38 prevents or limits air or other gasesfrom escaping from the combustion chamber 21. The cylinder head 37 mayhave a plurality of apertures provided in it to receive various enginecomponents. A first aperture may provide an intake port that may beselectively blocked and unblocked by an intake poppet valve 26. A secondaperture may provide an exhaust port that may be selectively blocked andunblocked by an exhaust poppet valve 32. A third aperture may receive aspark plug 53 for spark ignition engines, or a glow plug for Dieselengines. A fourth aperture may receive a direct fuel injector 54.Additional apertures may be provided in the cylinder head 37 foradditional intake valves, exhaust valves, auxiliary valves, spark plugs,glow plugs, fuel injectors and/or water injectors. Preferably, theintake poppet valve(s) 26, exhaust poppet valve(s) 32, spark plug(s) 53,direct fuel injector(s) 54, and water injector (not shown), are providedat or near central locations of the cylinder head 37.

The elongated stems of the intake poppet valve 26 and the exhaust poppetvalve may be biased toward their respective cam followers 29 by valvesprings 27. The cam followers 29 may pivot about hydraulic lifters 30under the influence of the cams 28. The hydraulic lifters 30 may becontrolled to provide Variable Valve Actuation, although this is notrequired, in which case the hydraulic lifters may be used to simplyadjust valve lash. The valve springs 27 may bias the intake and exhaustpoppet valves 26 and 32 into closed positions when their respective cams28 are at base circle with respect to the cam followers 29. It isappreciated that the foregoing described valve train arrangement may bemodified without departing from the intended scope of the presentinvention. Different combinations of mechanical, electrical and/orhydraulic components may be employed to actuate the intake and exhaustpoppet valves.

The piston 36 may be slidably disposed in the engine block 38 below thecylinder head 37. The piston 36 may have a piston head 22 at an upperend, a lower end, and a side wall or piston skirt 35 extending betweenthe upper end and the lower end of the piston. The piston skirt 35 maybe generally non-cylindrically shaped, and the piston head 22 may bedomed cooperatively with the upper end wall of the combustion chamber21. One or more depressions 23 may be formed in the piston head 22. Whenviewed from above, looking down into the combustion chamber 21, theouter perimeters of the piston skirt 35 and the piston head 22 may havea non-circular cross-sectional shape, preferably a generally rectangularshape with rounded corners. The cylinder may have a matchingcross-sectional shape. The term “rectangular” refers to a shape withfour straight edges joined at four rounded ninety-degree corners whereinthere are at least two opposing pairs of straight edges that are thesame length separated by rounded corners, or all four of the straightedges are the same length (square) separated by rounded ninety-degreecorners. The dimension of the rounded corners may vary, and in someembodiments may occupy a dominant portion of the rectangle side.

The curvature of the outer surface of the piston head 22 may bepreferably hemispherical or semi-hemispherical, and may have asubstantially constant radius of curvature. The upper dome of the pistonhead 22 may extend between diametrically opposed edges of the pistonskirt 35, and thus the diameters of the piston skirt 35 and the upperdome may be substantially the same. The upper dome may have anupper-most crown or apex that may be located at a point spaced from orcoincident with a reference axial centerline extending through thecenters of the upper dome and piston skirt 35. In other words, the apexmay be off-center and proximal to the one side of the engine cylinder inwhich the piston 36 is disposed, or may be on-center relative to theengine cylinder.

With reference to FIGS. 1 and 2, the piston 36 may be attached to across-head 34 which is slidably received by an upper cross-head guide 33and a lower cross-head guide 43. The upper cross-head guide 33 and lowercross-head guide 43 constrain the cross-head 34 to purely linear motion.The lower portion of the cross-head 34 may extend past the lowercross-head guide 43 into the oil reservoir 45. Rapid dipping andundipping of the cross-head 34 into the oil reservoir 45 may create oilsplash that lubricates the engine components in the crankcase 39. Theupper cross-head guide 33 may form a barrier that prevents oil fromentering the lower (supercharger) chamber 51 from the crankcase 39, andthat prevents gases in the lower chamber from entering the crankcase.One or more drain passages 44 may extend between the crankcase 39 andthe oil reservoir 45.

With continued reference to FIGS. 1 and 2, the cross-head 34 may bepivotally connected to two connecting rods 42 by a wrist pin 31 locatedbetween the upper cross-head guide 33 and the lower cross-head guide 43.Each connecting rod 42 is aligned parallel with and rigidly connected tothe other connecting rod by the wrist pin 31. The connecting rod 42 andwrist pin 31 may be connected using a weld, pin, press fit, interlockingshape, or locking screws, for example. The wrist pin 31 may have anaxial dimension that is parallel with, but spaced from, an axialdimension of the crankshaft 41. The two connecting rods 42 may bedisposed on opposite sides of the cross-head 34. The ends of theconnecting rods 42 that are distal from the wrist pin 31 may bepivotally connected to respective cranks 40 disposed on opposite sidesof the cross-head 34. Each of the cranks 40 may be connected to a splitcrankshaft comprised of two coaxial crankshaft sections 41 disposed onopposite sides of the cross-head 34. Each crank 40 may have an offset(i.e. the distance between (i) the pivot point of the crank 40 andconnecting rod 42 and (ii) the axis of the crankshaft 41) equal to halfof the appropriate stroke length of the piston 36.

FIG. 6 illustrates a preferred manner of connecting a crank 40 to acrankshaft section 41. The bore provided in the crank 40 for receivingthe crankshaft 41 may have a plurality of crank keyholes 67 formed inthe bore side wall. The crankshaft 41 may have a matching set ofcrankshaft keyholes 68 formed around the outer circumference of one endof the crankshaft. Pins/keys 58 may be inserted into either the crankkeyholes 67 or the crankshaft keyholes 68, after which the crank 40 andcrankshaft 41 may be press fit together to form a rigidly connectedcrank and crankshaft assembly. The number, size, shape, and material ofthe pins/keys 58 may be selected to allow the pins/keys to shear withacceptable damage if the assembly is subjected to detrimental levels ofacceleration, deceleration, non-circular motion, or over-limit torque.Shearing pins/keys 58 may permit the connected crank 40 and crankshaft41 to disengage and prevent transmission of unacceptable forces to othercomponents in the engine and drive train. Shearing pins/keys 58 mayallow the assembly to be more easily repaired with low cost parts aftera failure.

It is appreciated that the engine shown in FIG. 1 may includeconventional intake and exhaust poppet valves. However, FIGS. 7A-7E,inclusive, illustrate an alternative multi-stage engine poppet valve foruse as the intake poppet valve(s) 26 and/or exhaust poppet valve(s) 32in various embodiments of the present invention. With reference to FIG.7A, the multi-stage poppet valve may include a cooperatively shaped andsized inner poppet valve 60 and an outer poppet valve 59. The outerpoppet valve 59 may have an upper elongated hollow stem 73, a lowervalve head/seat 75, and an intermediary cage body 74. The cage body 74may include a plurality of fingers 76 that connect the upper elongatedhollow stem 73 to the lower valve head/seat 75. The lower valvehead/seat 75 of the outer poppet valve 59 may have a port or opening 79extending through it from a lower face to the cage body 74. The innerpoppet valve 60 may have an upper elongated stem 77 and a lower valvehead 78.

With reference to FIGS. 7B, 7D and 7E, the stem 77 of the inner poppetvalve 60 is configured to slide securely within the hollow stem 73 ofthe outer poppet valve 59. The head 78 of the inner poppet valve 60 isconfigured to seal against the head/seat 75 of the outer poppet valve 59to block the port 79 when the inner poppet valve is in a valve-closedposition. The head/seat 75 of the outer poppet valve 59 is configured toseal against the valve seat 62 to block the port 80 when the outerpoppet valve is in a valve-closed position. When the outer poppet valve59 and inner poppet valve 60 are in valve-closed positions, as shown,the flow of working fluid through ports 79 and 80 is prevented. Theouter poppet valve 59 encompasses the inner poppet valve 60 and theouter poppet valve head/seat 75 mates with a sealing surface on theinner poppet valve head 78.

With reference to FIG. 7C, the outer poppet valve 59 and the innerpoppet valve 60 are shown in a valve-opened position for the passage ofworking fluid past the valve. Actuation of the outer poppet valve 59causes the outer poppet valve to translate downward away from the valveseat 62, and (optional) actuation of the inner poppet valve 60 causes itto translate upward away from the outer poppet valve head/seat 75. Theseactuations, together or independently, permit working fluid to flow pastthe valve as the result of an outer flow 63 and/or an inner flow 64.

The inner poppet valve 60 may be manufactured by forging using dies toobtain stronger structures and better grain orientation, or turned on alathe, for example. The outer poppet valve 59 may be progressivelyforged as a flat piece and then forged and bent progressively untilU-shaped similar to the way sheet metal parts are shaped into 3Dstructures. The inner poppet valve 60 and outer poppet valve 59 assemblymay be completed by inserting the inner poppet valve into the U-shapedouter poppet valve and pressing it closed. The resulting seam may beleft slightly open or welded followed by a grind and polish process.

Alternatively, the inner poppet valve 60 may be made of two or morepieces where the stem 77 is separate from the head 78, for example. Theinner poppet valve head 77 piece or pieces may be inserted throughopenings in the outer valve 59 cage body 74 and connected to the innerpoppet valve 60 stem 77 using threads, pins, press-fit, welding, orother connection type. In other alternative examples, the outer poppetvalve 59 and inner poppet valve 60 assembly may be manufactured using alaser sinter (rapid manufacturing/3D print) process, or investmentcasting/lost wax process, or fine die casting using cores. Other methodsof manufacturing the described multi-stage valve may be employed withoutdeparting from the intended scope of the invention.

FIG. 8A illustrates an example of a valve actuation system that may beused to actuate a multi-stage poppet valve having an outer poppet valve59 and an inner poppet valve 60 in accordance with the first embodimentof the present invention. A hydraulic lifter 30 may be supported at alower end by a fixed structure such as the cylinder head. The upper endof the hydraulic lifter 30 may pivotally support the first end of a camfollower 29. The cam follower 29 may contact the cam 28. The end of thecam follower 29 distal from the lifter 30 may contact the outer poppetvalve stem 73 such that downward motion of the cam follower end pushesthe outer poppet valve stem downward against the upward bias of thevalve spring 27. The cam follower 29 end may be forked so that itsdownward motion does not cause the inner poppet valve stem 77 to move.The inner poppet valve 60, including its stem 77, may be held in a fixedposition by a fixed mount 61.

The position of the pivot point between the lifter 30 and the camfollower 29 relative to the cam 28 may be adjusted during engineoperation to adjust lash. The pivot point may also be adjusted rapidlyon an engine cycle-to-cycle basis to provide variable valve actuation.When the pivot point is held in a fixed position, even if only briefly,rotation of the cam 28 pushes the cam follower 29 downward about thepivot point, which in turn pushes the outer poppet valve stem 73downward. The downward motion of the outer poppet valve stem 73 pushesthe valve head/seat 75 downward and away from the seat 62 and the innerpoppet valve head 78 (see FIG. 7C). This manner of valve actuation maybe used to provide any needed valve opening events.

With renewed reference to FIG. 1, the piston 36 may be disposed withinthe combustion chamber 21 such that the piston skirt 35 is closelyaligned with, but uniformly spaced from and parallel to, the side wallof the combustion chamber. The upper end wall and side wall of thecombustion chamber 21, together with the piston head 22, may form aworking space or compression area 24 which may receive a working fluid.The piston 36 may be configured to slide within the combustion chamber21, reciprocally towards and away from the combustion chamber 21 upperend wall.

With reference to FIGS. 1, 4A, 4B and 4C, the piston skirt 35 may have aringless fluid scaling system 25 comprised of a plurality of recesses orpockets separated by lands forming a field of pockets. Preferably, thepockets may be of like shape and dimension in terms of shape at themouth, shape at the base, height, width, diameter, depth, and/or volume.Preferably, the piston skirt 35 is a hollow wall structure (i.e., notsolid between opposing outer points) and the pockets are formed inpiston skirt but do not extend through the piston skirt to the hollowinterior of the piston 36. The pockets in the field 25 may be arrangedin at least one circumferential row, or more preferably, in a gridpattern consisting of two or more vertically spaced rows of pockets. Thenumber, shape, size and arrangement of the lands and pockets in thefield 25 shown in the drawing figures was selected for ease ofdiscussion and illustration and is not considered limiting.

A seal or seal equivalent may be produced over the expanse of the pistonskirt 35, from top to bottom, due to the presence of the pockets andlands arranged in an appropriate sealing system field 25 on the face ofthe piston skirt. The seal or its equivalent may be generated as theresult of the pressure difference of the working fluid between thecombustion chamber 21 and the lower chamber 51. As the piston 36 movesupward in the combustion chamber 21, the pressure and temperature of theworking fluid in the working space 24 may rise and produce a workingfluid pressure differential between the combustion chamber 21 and thelower chamber 51. This pressure differential may cause the working fluidin the space between the piston skirt 35 side wall and the chamber sidewall, i.e., flow in the seal gap, to flow towards the lower chamber 51.Flow of the working fluid through the seal gap may induce a localVenturi effect at each pocket in the field 25, which may locallyincrease the speed and decrease the pressure of the working fluid. Thespeed and pressure change of the working fluid may be a function of thepractical small clearance distance between the piston skirt 35 side walland the combustion chamber 21 side wall.

With continued reference to FIGS. 1, 4A. 4B and 4C, the pocketspreferably may have relatively sharp edges at the junction with the faceof the piston skirt 35, i.e., at the junction with the lands. As theworking fluid flows over the sharp edge of a pocket, a decrease in localpressure may occur due to turbulence. As a result, the working fluid mayexpand creating a momentary decrease in pressure and an increase oflocalized turbulence. Further working fluid flowing over and into eachsuccessive pocket may begin a cycle wherein each pocket serves as aHelmholtz-like resonator or resonating column (dependent upon pocketshape deployed), which may cause the working fluid to be drawn into andexpelled out of the pocket at a definable frequency creating furtherlocalized turbulence.

The resulting turbulence may be a function of the physical properties ofthe working fluid in the system and the diameter (or height and width),geometry, relational location, and depth of each individual pocket inthe field 25. The resulting turbulence may also be a function of thepractical small clearance distance or seal gap due to the ratio of thespatial volume above each land to the spatial volume above and withineach pocket. This localized turbulence may interact with the flowingworking fluid and generate a vortex motion that impedes further flow ofthe working fluid. The decrease in flow may momentarily decrease theresonance effect, which in turn may momentarily decrease the localizedturbulence, which then may allow the flow rate of the working fluid tomomentarily increase again.

When the piston 36 is on an upward stroke, the working fluid which haspassed over the pockets in the upper most row (closest to the pistonhead 22) may next encounter the pockets in the adjacent row of thepocket field 25 where the described turbulence phenomena repeats, but ata lower starting pressure. This process may repeat as the working fluidpasses over successive rows of the sealing system pocket field 25 withsuccessively relatively decreased starting pressure until the localpressure in the seal gap is reduced to the pressure level of the workingfluid contained in the lower chamber 51. The repeating cycle of pressurereduction from pocket to pocket in the field 25 may create a seal or theeffective equivalent of a seal since no working fluid will flow past thepoint at which the local pressure in the seal gap is at or below thepressure of the working fluid in the lower chamber 51.

The localized turbulence at each pocket may decrease with time due tothe gradual leaking allowed by the resonant action of the pockets.Therefore, the localized turbulence may also be a function of the rateof motion of the piston 36 relative to the combustion chamber 21 sidewall, as the motion may be responsible for the pressure changes aroundthe piston 36 in the combustion chamber. The effectiveness of thescaling system may require working fluid pressures that fluctuate toprovide energetic flows into the sealing system field 25 by providing aconsistent flow in and out of the pockets, thereby maintaining theeffectiveness of the sealing system.

The rate of the sealing system leakage may be modified by usingdifferent land spacing patterns and pocket geometries within the sealingsystem field 25. The land spacing may be selected to induce the pocketsto provide counter flow to prior (upper) pockets while forward (lower)pockets may prevent fluid flow to induce internally decayingself-reinforcing oscillations within the sealing system field 25.

The effectiveness of the sealing system field 25 for a particularapplication may be a function of the outside dimensions of the sealingsystem field in addition to the design parameters of the individualpockets. The seal efficiency may be improved by modifying the geometryof some or all of the pockets to include a convergent area at the innerbase of the pockets and a divergent area at the mouth of the pockets. Ade Laval nozzle effect may be produced at the pockets using a convergentarea and a larger divergent area to form a resonant cavity at the bottomof the pockets, which may create greater localized turbulence due tolocalized supersonic working fluid movement.

With reference to FIG. 1, the piston 36 may self-center within thecombustion chamber 21 due to the tendency of the pressure surroundingthe piston to normalize at any given vertical point on the piston skirt35. For example, when the practical small clearance distance, i.e., theseal gap, between the piston 36 and the surrounding cylinder aremomentarily unequal about a central axis, a total normalizing force maybe generated by the pressures acting on the surface area of the opposingsides of the piston. This total normalizing force may urge the piston 36to be centrally located within the cylinder with a dampened oscillationabout the central axis. With additional reference to FIGS. 4A and 4C,the time required for the normalizing force to return the piston to thecenter of the cylinder may be decreased by adding one or more equalizinggrooves 69. The equalizing grooves 69 may be disposed on land areas, orbetween pockets, or both on land areas and between pockets, or in theside wall of the chamber 21 opposing the pockets to allow a more uniformdistribution of the forces more rapidly on the surface employing thesealing system.

It is appreciated that the field 25 of pockets, and/or the equalizinggrooves 69, described as being formed on or in the surface of the piston36 may instead be formed on or in the surface opposing the piston inalternative embodiments. It is also appreciated that the field 25 ofpockets described as being formed on or in the surface of the piston 36may also be formed on or in the surface opposing the piston in additionto being formed on or in the surface of the piston. It is alsoappreciated that the field of pockets may be used on pistons like thoseillustrated in FIGS. 4A, 4B and 4C, or on other pistons of different(i.e., non-rectangular) shape, with or without depressions 23.

With reference to FIGS. 1, 4A, 4B and 4C, details of the depressions 23formed in the piston 36 are illustrated. There may be one depression 23(left side of figure) provided for a corresponding intake poppet valve26 and another depression 23 (right side of figure) provided for acorresponding exhaust poppet valve 32. The depressions 23 may each havea continuous, generally circular, side wall extending between an upperlip and a depression floor. Each of the depression side walls may becurved in two dimensions—from upper lip to depression floor, and in aplane substantially parallel to the depression floor so as to begenerally circular when viewed from above. Alternatively, the side wallsmay be ramped in the floor to upper lip dimension instead of curved inthat direction. The height of the depression side walls (i.e., thevertical distance between the upper lip and the depression floor) mayvary along its length, preferably having a maximum height at a pointproximal to the center of the piston 36 and a minimum height at a pointdistal from the center of the piston. The curved shape of the depression23 side walls in the upper lip to depression floor direction may vary,but is preferably spherical. The depression floors may be generally flator curved to a lesser degree than the side walls. The size of thedepressions 23 may also vary, but preferably the depressions have alarger diameter at the upper lip than at the depression floor.

The depression floor of each depression 23 may be set at an anglerelative to the straight edge formed by the junction of the piston skirt35 with the piston head 22, as shown in FIG. 4C. The angle at which thedepression floor is set may match the angle made between theaforementioned straight edge and the lower edge of the correspondingintake poppet valve 26 or exhaust poppet valve 32 for the depression 23.The depressions 23 may be located on the piston head 22 and sized suchthat the corresponding intake valve 26 or exhaust valve 32 may operateand if needed, extend into the depression, without making contact withthe piston 36. The intake poppet valve 26 and/or exhaust poppet valve 32may be positioned above their respective depression 23 such that theegress path for working fluid squished between the poppet valve and thedepression when the two are moving towards each other is larger near thecenter of the piston 36 than elsewhere. The shapes and/or sizes of thedepressions 23 formed in the same piston 36 may be different from eachother, and when two opposing depressions 23 are provided, they may belocated equidistant from the center of the piston 36, as shown, oralternatively, set at different distances from the center of the piston.The depressions 23 are preferably configured to improve the flow ofworking fluid into and out of the combustion chamber 21. It isappreciated that the depressions 23 may be used on pistons like thoseillustrated in FIGS. 4A, 4B and 4C, or on other pistons of different(i.e., non-rectangular) shape.

The engine shown in FIG. 1 may operate as follows for positive powerengine operation. The intake poppet valve 26 is opened on the intakestroke of the piston 36 by the intake side cam 28 and cam follower 29against the closing bias of the valve spring 27. At the same time, theexhaust poppet valve 32 may be in the process of closing under thecontrol of the exhaust side cam 28 and cam follower 29. The open intakepoppet valve 26 allows air or charge to blow-down into the upper chamber21 of the cylinder and aids the scavenging and evacuation of exhaustgases through the closing, but not yet closed, exhaust poppet valve 32.As the intake stroke continues, the exhaust poppet valve 32 closes whileadditional air or charge is drawn into the upper chamber 21 from theintake poppet valve 26. The charge may be developed outside of thecylinder near the intake poppet valve 26 passage by a port fuel injector55 (shown in FIG. 3) with appropriate timing to allow the fuel toadequately vaporize and mix near the intake valve passage. The chargealso may be developed within the upper chamber 21 by a direct fuelinjector 54. The direct fuel injector may operate during either or bothof the piston 36 movement directions. Alternatively, a combination ofthe two fuel injection strategies, port injection and direct injection,may be used. The combination strategy may be important for high RPMoperation because there may be insufficient time for proper atomization,vaporization, and mixing of the fuel with gasses when only directinjection is used at high RPMs.

The intake event ends as the piston 36 passes bottom dead centerposition and begins its ascent in the cylinder. As the piston 36 rises,the charge in the cylinder is compressed in the upper chamber 21. Squishand swirl may be created above the hemispherical crown of the piston 36by depressions 23. Turbulence may be induced in the form of squish andswirl as the charge is forced into the compression area 24 where thespark plug 53 is allowed to come into intimate contact with thecompressed charge. The spark plug 53 ignites the charge at theappropriate time or times and allows the flame front to propagatethrough the charge in the centrally contained volume. This promotes amore uniform flame front travel and subsequent faster flame frontpropagation as the gasses are agitated and expand, urging the piston 36downward. This transfers the thermodynamic chemical energy throughpressure acting upon the surface of the piston 36, which transfers theenergy through the cross-head 34 into the connecting rod 42 by way ofthe wrist pin 31, then through the crank 40, to ultimately turn thecrankshaft 41. The momentum stored within the crank 40 carries themechanism through bottom dead center and urges the piston 36 upwards asthe valve train opens the exhaust poppet valve 32 to allow theevacuation of the gasses. This cycle continues ad infinitum as theengine runs. Oil is delivered from the oil reservoir 45 to bearings andseals as necessary via conventional means of a pump and passages (notillustrated) within the appropriate elements of the engine and withinthe one or more-piece engine block 38 and crank case 39, which also hasdrain passages 44 to allow the oil return to the oil reservoir 45.

FIG. 3 illustrates a second engine embodiment of the present invention.In the FIG. 3 embodiment, two openings are formed in the side wall ofthe sealed lower (supercharger) chamber 51 formed between the lower edgeof the piston skirt 35 and the upper cross-head guide 33. Each openingis provided with a one-way reed valve 46. The first one-way valve 46permits working fluid (e.g., air) to flow from a source of fresh air 48into the lower chamber 51, but not in the reverse direction to anysubstantial degree. The second one-way valve 46 permits the workingfluid 52 to be pumped from the lower chamber 51 into an intercooler 50where it is stored as compressed working fluid 49. The compressed air 49may be cooled and stored until needed. The second one-way valve 46prevents or limits back flow of working fluid from the intercooler 50 tothe lower chamber 51. A port fuel injector 55 may inject fuel into thecompressed air 49. Thereafter, the compressed working fluid or air 49and fuel mixture in the intercooler 50 may flow into the combustionchamber 21 under the control of the intake poppet valve 26.

The flow of working fluid progressively from the source of fresh air 48to the lower chamber 51, and from the lower chamber 51 to theintercooler 50, results from the pumping motion of the piston 36. Whenthe piston 36 is stroking upward, the resulting vacuum force drawsworking fluid from the fresh air source 48 through the first one-wayvalve 46 while at the same time drawing the second one-way valve shut.When the piston 36 strokes downward, the resulting compressive forcepushes the working fluid 52 from the lower chamber 51 past the secondone-way valve 46 into the intercooler 50 while at the same time pushingthe first one-way valve 46 closed. The upward motion of the piston 36pushes exhaust gases 47 past the exhaust poppet valve 32. It isappreciated that a sealed lower chamber 51 with two one-way check valves46 may be used on engines having different piston shapes, differentpoppet valves, etc., than those illustrated in FIG. 3.

It is also appreciated that the pumping action of the piston 36, ormultiple pistons together, may be used in alternative embodiments tocharge a common reservoir or plenum with pressurized air. Thepressurized reservoir or plenum may be used to supply air to the intakemanifold servicing the one or more intake poppet valves 26.

Another alternative engine embodiment of the present invention mayinclude engine pistons of the type illustrated in FIGS. 5A, 5B and 5C,which show a rectangular piston 36 that differs from the piston of FIGS.4A, 4B and 4C in the following regard. In FIGS. 5A-5C, the piston 36does not include a ringless fluid sealing system 25 comprised of a fieldof pockets, but instead includes one or more piston rings 56 to form aseal with the combustion chamber. The piston 36 of FIGS. 5A, 58B and 5Cfurther includes an S-shaped guiding projection 57 that forms a barrierat the surface of the piston head 22 between the two depressions 23. Theguiding projection 57 may have a generally rectangular cross-sectionwith a generally flat top surface and two opposing generally flat sidewalls. The guiding projection 57 may also extend from the upper lip of afirst depression 23 at a point proximal to a first side of the piston 36to the upper lip of a second depression 23 at a point proximal to asecond opposite side of the piston to form an S-shape when viewed fromabove (FIG. 5B). The guiding projection 57 may have ramps that slope upat each end to a maximum height measured from the base of the guidingprojection to the top edge or surface. The height of the guidingprojection 57 may vary over its length between the end ramps. In apreferred embodiment, the height of the guiding projection 57 may begreatest at points between the end ramps and the center of the S-shape(i.e., center of the piston 36). The S-shape of the guiding projection57 may be gently curved from end-to-end. The overall shape and size ofthe guiding projection 57 may be selected to urge the flow of workingfluid in the combustion chamber in a manner that promotes combustionand/or exhaust processes. It is appreciated that the guiding projection57 may be used on pistons like those illustrated in FIGS. 4A, 4B and 4C,or on other pistons of different (i.e., non-rectangular) shape, with orwithout depressions 23.

A fourth engine embodiment of the present invention includes poppetvalves of the type illustrated in FIGS. 7F, 7G, 7H and 7I, in which likeelements from other embodiments are labeled with like referencecharacters. FIG. 7F shows the alternative multi-stage poppet valve alsomay include a cooperatively shaped and sized inner poppet valve 60 andan outer poppet valve 59. The outer poppet valve 59 may have a hollowupper stem 73, lower valve head/seat 75, and an intermediary cage body74 that are formed together as a generally elongated hollow cylinder.The cage body 74 may include a plurality of fingers 76 that connect thehollow stem 73 to the lower valve head/seat 75. The lower valvehead/seat 75 of the outer poppet valve 59 may have a port or opening 79extending through it from a lower face to the cage body 74. The innerpoppet valve 60 may have an upper stem 77 and lower valve head 78 formedas a uniform diameter cylinder.

With reference to FIGS. 7G, 7H and 7I, the stem 77 of the inner poppetvalve 60 is configured to slide securely within the hollow stem 73 ofthe outer poppet valve 59. The head 78 of the inner poppet valve 60 isconfigured to seal against the head/seat 75 of the outer poppet valve 59to block the port 79 when the inner poppet valve is in a valve-closedposition. The head/seat 75 of the outer poppet valve 59 is configured toseal against the valve seat (not shown) to block the outer poppet valveport when the outer poppet valve is in a valve-closed position. When theouter poppet valve 59 and inner poppet valve 60 are in valve-closedpositions, the flow of working fluid through ports 79 and 80 isprevented. The outer poppet valve 59 encompasses the inner poppet valve60 and the outer poppet valve head/seat 75 mates with a sealing surfaceon the inner poppet valve head 78. With reference to FIGS. 7H and 7I,the outer poppet valve 59 and the inner poppet valve 60 are shown in avalve-opened position for the passage of working fluid past the valve.Actuation of the outer poppet valve 59 causes the outer poppet valve totranslate downward away from its valve seat, and (optional) actuation ofthe inner poppet valve 60 causes it to translate upward away from theouter poppet valve head/seat. These actuations, together orindependently, permit working fluid to flow past the valve as the resultof an outer flow 63 and/or an inner flow 64.

A fifth engine embodiment of the present invention includes a valveactuation system illustrated in FIG. 8B. FIG. 8B shows an alternativeexample of a valve actuation system that may be used to actuate amulti-stage poppet valve having an outer poppet valve 59 and an innerpoppet valve 60 in accordance with the first embodiment of the presentinvention. The valve actuation system in FIG. 8B differs from that ofFIG. 8A in the following regard. In the FIG. 8B embodiment, the innerpoppet valve 60, including its stem 77, is not held in a single fixedposition, but is biased by a second valve spring 27 into a closedposition. A second hydraulic lifter 30 for the inner poppet valve 60 issupported at a lower end by a fixed structure such as the cylinder head.The upper end of the second hydraulic lifter 30 may pivotally supportthe first end of a second cam follower 29. The cam follower 29 maycontact a second cam 28 for actuation of the inner poppet valve 60. Theend of the second cam follower 29 distal from the second lifter 30 maycontact the inner poppet valve stem 77 such that downward motion of thesecond cam follower end pushes the inner poppet valve stem downward. Thedownward motion of the inner poppet valve 60 may be selectively set tomatch the downward motion of the outer poppet valve 59 to block theinner flow 64 (see FIG. 7C) in whole or in part during the downwardmotion of the outer poppet valve. Alternatively, the downward motion ofthe inner poppet valve 60 may act on the outer poppet valve 59 to pushthe outer poppet valve 59 open but keep the inner flow 64 blocked (seeFIG. 7C). The position of the pivot point between the second lifter 30and the second cam follower 29 relative to the second cam 28 may beadjusted during engine operation in the same manner as described abovefor the valve train components servicing the outer poppet valve 59.

FIG. 8C illustrates the use of the valve actuation system shown in FIG.8A with the outer poppet valve 59 and inner poppet valve 60 assemblyshown in FIGS. 7F-7I.

An internal combustion engine in accordance with a sixth embodiment ofthe present invention is shown in FIG. 9, in which like elements arelabeled with like reference characters. FIG. 9 illustrates a V-bankedengine with pistons 36 and other components of the type shown in FIG. 3wherein the overall engine is “inverted” as compared with the engineshown in FIG. 3. An engine is considered to be inverted when it isoriented such that all engine pistons 36 in the engine have a pistonhead 22 with a location thereon that is continually closer to the centerof gravity of the local gravitationally dominant body (e.g., Earth) thanany location on the same piston's skirt 35 for a prolonged period oftime. An inverted engine may also be defined as one in which the pistonsare closer to the local gravitationally dominant body's center ofgravity at top dead center position than at bottom dead center positionduring normal operation. For example, an engine provided in a wheeledvehicle is inverted if all of the engine pistons 36 have a piston head22 with a location thereon that is continually closer to the center ofgravity of the Earth than any location on the piston's skirt 35 whilethe vehicle is resting on level ground. In another example, an engineprovided in an aircraft is inverted if the engine pistons 36 have apiston head 22 with a location thereon that is continually closer to thecenter of gravity of the Earth than any location on the piston's skirt35 for the majority of the time that the aircraft is in flight.

The engine shown in FIG. 9 differs from that shown in FIG. 3 in thefollowing regard. The engine of FIG. 9 includes an oil reservoir used toprovide lubricant to the crankcase 39 which is located next to theinverted piston 36 cylinders. As a result, the intercooler 50 passesthrough the oil reservoir 45 which assists in cooling the working fluidwithin the intercooler.

An internal combustion engine in accordance with a seventh embodiment ofthe present invention is shown in FIGS. 10A and 10B, in which likeelements are labeled with like reference characters. FIGS. 10A and 10Billustrate an alternative inverted engine. The FIGS. 10A and 10B enginediffers from that shown in FIG. 9 in the following regard. The FIGS. 10Aand 10B embodiment may use in-line engine pistons 36 and a splitcrankshaft assembly of the type described in connection with FIGS. 10Cand 10D instead of ringless, non-lubricated pistons. In FIG. 10C, acrankshaft bearing 66 may be provided with an oil passage that receivespressurized oil from an oil source 65. The bearing 66 oil passagecommunicates with a chain of oil passages extending from the bearingthrough the split crankshaft 41, crank 40, connecting arm 42, wrist pin31, cross-head 34, and piston skirt 35. The oil may flow through thesepassages to one or more bleed holes 70 provided on the surface of thepiston skirt 35 between piston rings 56. Oil may be taken in from thesurface of the piston skirt by return holes 71 extending through thepiston skirt 35. Returned oil may spill from return port 72 into thecrankcase to lubricate the split crankshaft assembly.

The FIGS. 10A and 10B engine may also use a modified superchargerchamber 51 to provide supercharging of the combustion chamber 21 withpressurized air/charge. In FIGS. 10A and 10B, the supercharger chamber51 may be defined in part by a space between the piston skirt 35 and theupper cross-head guide 43, and also in part by a space adjacent to thepiston cylinder. This adjacent space may comprise an intercooler, apressurized reservoir or plenum, or both. One or more passages mayconnect the two spaces (space above the piston skirt 35 and adjacentspace). The use of one or more connecting passages may limit the amountof lubricating oil that migrates from the piston skirt to the adjacentspace from where it could enter the compression chamber 21.

As will be understood by those skilled in the art, the invention may beembodied in other specific forms without departing from the spirit oressential characteristics thereof. The elements described above areillustrative examples of one technique for implementing the invention.One skilled in the art will recognize that many other implementationsare possible without departing from the intended scope of the presentinvention as recited in the claims. For example, embodiments of theinvention may be used in engines that are 2-cycle, 4-cycle, ormulti-cycle, and that utilize any type of fuel, such as gasoline,bio-gasoline, natural gas, propane, alcohol, bio-alcohol, diesel,bio-diesel, hydrogen, gasified carbonaceous, bio-mass, or blended fuels.Accordingly, the disclosure of the present invention is intended to beillustrative, but not limiting, of the scope of the invention. It isintended that the present invention cover all such modifications andvariations of the invention, provided they come within the scope of theappended claims and their equivalents.

What is claimed is:
 1. An internal combustion engine comprising: anengine cylinder having a cylinder wall; a piston disposed in the enginecylinder, said piston having a skirt and a head; a combustion chamberadjacent to the piston head defined by the cylinder wall; a firstcross-head guide disposed proximal to the piston; a second cross-headguide disposed distal from the piston; a cross-head connected to thepiston, said cross-head extending between and slidably received by thefirst cross-head guide and the second cross-head guide; two connectingrods each having a first end pivotally connected to the cross-head, anda second end distal from the first end, wherein the two connecting rodsare disposed on opposites sides of the cross-head and rigidly connectedto each other; a first crank disposed in a crankcase and pivotallyconnected to the second end of a first of the two connecting rods; asecond crank disposed in the crankcase and pivotally connected to thesecond end of a second of the two connecting rods; a first splitcrankshaft section connected to the first crank; and a second splitcrankshaft section connected to the second crank.
 2. The internalcombustion engine of claim 1, wherein the engine cylinder has agenerally rectangular cross-section with rounded corners, and whereinthe piston has a generally rectangular cross-section with roundedcorners.
 3. The internal combustion engine of claim 2, wherein thepiston head includes an upper dome.
 4. The internal combustion engine ofclaim 1, further comprising a plurality of laterally spaced pocketsarranged in a plurality of rows to form a field of pockets on but notextending through the piston skirt, or on but not extending through theengine cylinder, or on but not extending through both the piston skirtand the engine cylinder.
 5. The internal combustion engine of claim 1,wherein the engine cylinder and piston are in an inverted orientation.6. The internal combustion engine of claim 1, further comprising: asupercharger chamber defined at least in part by a space between thepiston skirt and the first cross-head guide; a first opening in thesupercharger chamber; a second opening in the supercharger chamber; aworking fluid passage extending from the second opening to thecombustion chamber; a first one-way valve disposed in the first opening,said first one-way valve configured to permit flow from a source offresh air into the supercharger chamber; and a second one-way valvedisposed in the second opening, said second one-way valve configured topermit flow from the supercharger chamber to the working fluid passage.7. The internal combustion engine of claim 1, further comprising: afirst poppet valve disposed in the engine cylinder; and a firstdepression formed in said piston head proximal to the first poppetvalve, wherein the first depression has a continuous, generallycircular, side wall extending between an upper lip and a depressionfloor, and wherein the first depression side wall is curved or rampedfrom the upper lip to the depression floor.
 8. The internal combustionengine of claim 7, further comprising: a second poppet valve disposed inthe engine cylinder; and a second depression formed in said piston headproximal to the second poppet valve, wherein the second depression has acontinuous, generally circular, side wall extending between an upper lipand a depression floor, and wherein the second depression side wall iscurved or ramped from the upper lip to the depression floor.
 9. Theinternal combustion engine of claim 1, further comprising a poppet valveassembly including: an outer poppet valve with a hollow stem, lowerhead, and intermediary cage connecting the hollow stem to the lowerhead; and an inner poppet valve having a stem and a lower head, saidinner poppet valve stem slidably disposed in the outer poppet valvehollow stem, and said inner poppet valve head movable within said outerpoppet valve intermediary cage.
 10. The internal combustion engine ofclaim 1, further comprising: an oil reservoir connected to the crankcaseby one or more drain passages, wherein the cross-head includes a lowerextension configured to agitate oil in the oil reservoir as a result ofengine operation.
 11. The internal combustion engine of claim 10,further comprising: a plurality of crank keyholes formed in the firstcrank; a plurality of crankshaft keyholes formed in the first splitcrankshaft section; and a plurality of pins/keys disposed in andextending between the plurality of crank keyholes and the plurality ofcrankshaft keyholes.
 12. The internal combustion engine of claim 1,further comprising: a plurality of crank keyholes formed in the firstcrank; a plurality of crankshaft keyholes formed in the first splitcrankshaft section; and a plurality of pins/keys disposed in andextending between the plurality of crank keyholes and the plurality ofcrankshaft keyholes.
 13. An internal combustion engine comprising: anengine cylinder having a cylinder wall; a piston disposed in the enginecylinder, said piston having a skirt and a head; a combustion chamberadjacent to the piston head defined by the cylinder wall; a firstcross-head guide disposed proximal to the piston; a second cross-headguide disposed distal from the piston; a crankcase disposed between thefirst cross-head guide and the second cross-head guide; a cross-headconnected to the piston, said cross-head extending between and slidablyreceived by the first cross-head guide and the second cross-head guide,said cross-head having a lower extension; and an oil reservoir connectedto the crankcase by one or more drain passages, wherein the cross-headlower extension is configured to agitate oil in the oil reservoir as aresult of engine operation.
 14. The internal combustion engine of claim13, wherein the engine cylinder has a generally rectangularcross-section with rounded corners, and wherein the piston has agenerally rectangular cross-section with rounded corners.
 15. Theinternal combustion engine of claim 13, further comprising a pluralityof laterally spaced pockets arranged in a plurality of rows to form afield of pockets on but not extending through the piston skirt, or onbut not extending through the engine cylinder, or on but not extendingthrough both the piston skirt and the engine cylinder.
 16. The internalcombustion engine of claim 13, wherein the engine cylinder and pistonare in an inverted orientation.
 17. The internal combustion engine ofclaim 13, further comprising: a supercharger chamber defined at least inpart by a space between the piston skirt and the first cross-head guide;a first opening in the supercharger chamber; a second opening in thesupercharger chamber; a working fluid passage extending from the secondopening to the combustion chamber; a first one-way valve disposed in thefirst opening, said first one-way valve configured to permit flow from asource of fresh air into the supercharger chamber; and a second one-wayvalve disposed in the second opening, said second one-way valveconfigured to permit flow from the supercharger chamber to the workingfluid passage.
 18. The internal combustion engine of claim 13, furthercomprising: a first poppet valve disposed in the engine cylinder; and afirst depression formed in said piston head proximal to the first poppetvalve, wherein the first depression has a continuous, generallycircular, side wall extending between an upper lip and a depressionfloor, and wherein the first depression side wall is curved or rampedfrom the upper lip to the depression floor.
 19. The internal combustionengine of claim 13, further comprising a poppet valve assemblyincluding: an outer poppet valve with a hollow stem, lower head, andintermediary cage connecting the hollow stem to the lower head; and aninner poppet valve having a stem and a lower head, said inner poppetvalve stem slidably disposed in the outer poppet valve hollow stem, andsaid inner poppet valve head movable within said outer poppet valveintermediary cage.
 20. The internal combustion engine of claim 13,further comprising: a connecting arm connected to the cross-head; acrank connected to the connecting arm, said crank having a plurality ofcrank keyholes formed in the crank; a crankshaft section, saidcrankshaft section having a plurality of crankshaft keyholes formed inthe crankshaft section; and a plurality of pins/keys disposed in andextending between the plurality of crank keyholes and the plurality ofcrankshaft keyholes.
 21. An internal combustion engine comprising: anengine cylinder having a cylinder wall; a piston disposed in the enginecylinder, said piston having a skirt and a head; a combustion chamberadjacent to the piston head defined by the cylinder wall; a crankconnected through one or more members to the piston, said crank having aplurality of crank keyholes formed in the crank; a crankshaft member,said crankshaft member having a plurality of crankshaft keyholes formedin the crankshaft section; and a plurality of pins/keys disposed in andextending between the plurality of crank keyholes and the plurality ofcrankshaft keyholes.
 22. The internal combustion engine of claim 21,wherein the engine cylinder has a generally rectangular cross-sectionwith rounded corners, and wherein the piston has a generally rectangularcross-section with rounded corners.
 23. The internal combustion engineof claim 21, further comprising a plurality of laterally spaced pocketsarranged in a plurality of rows to form a field of pockets on but notextending through the piston skirt, or on but not extending through theengine cylinder, or on but not extending through both the piston skirtand the engine cylinder.
 24. The internal combustion engine of claim 21,wherein the engine cylinder and piston are in an inverted orientation.25. The internal combustion engine of claim 21, further comprising: asupercharger chamber defined at least in part by a space in which thepiston skirt reciprocates; a first opening in the supercharger chamber;a second opening in the supercharger chamber; a working fluid passageextending from the second opening to the combustion chamber; a firstone-way valve disposed in the first opening, said first one-way valveconfigured to permit flow from a source of fresh air into thesupercharger chamber; and a second one-way valve disposed in the secondopening, said second one-way valve configured to permit flow from thesupercharger chamber to the working fluid passage.
 26. The internalcombustion engine of claim 21, further comprising: a first poppet valvedisposed in the engine cylinder; and a first depression formed in saidpiston head proximal to the first poppet valve, wherein the firstdepression has a continuous, generally circular, side wall extendingbetween an upper lip and a depression floor, and wherein the firstdepression side wall is curved or ramped from the upper lip to thedepression floor.
 27. The internal combustion engine of claim 21,further comprising a poppet valve assembly including: an outer poppetvalve with a hollow stem, lower head, and intermediary cage connectingthe hollow stem to the lower head; and an inner poppet valve having astem and a lower head, said inner poppet valve stem slidably disposed inthe outer poppet valve hollow stem, and said inner poppet valve headmovable within said outer poppet valve intermediary cage.
 28. A methodof lubricating a crankshaft assembly in an internal combustion engine,comprising the steps of: providing lubricant in an engine reservoir;providing a crankcase in which the crankshaft assembly including across-head operate, said cross-head having a lower extension thatcontacts the lubricant in the engine reservoir; and agitating thelubricant in the engine reservoir using motion of the lower extension ofthe cross-head.